This application claims priority benefit of Japanese Patent Application No. JP 2023-116451 filed in the Japan Patent Office on Jul. 18, 2023. Each of the above-referenced applications is hereby incorporated herein by reference in its entirety.
The present disclosure relates to a shunt resistance, a method of manufacturing the shunt resistance, and a semiconductor device.
Japanese Patent Laid-Open No. 2022-163238 discloses an example of a resistor in related art. The resistor disclosed in Japanese Patent Laid-Open No. 2022-163238 includes a resistive element and a pair of electrodes. This resistor is configured as a shunt resistor.
A preferred embodiment of the present disclosure will hereinafter be described specifically with reference to the drawings.
Such terms as “first,” “second,” and “third” in the present disclosure are used simply for identification, and permutation is not intended to be applied to target objects of these terms.
In the present disclosure, unless otherwise noted, a “certain object A being formed in a certain object B” and the “certain object A being formed on the certain object B” include the “certain object A being directly formed in the certain object B” and the “certain object A being formed in the certain object B while another object is interposed between the certain object A and the certain object B.” Similarly, unless otherwise noted, the “certain object A being disposed at the certain object B” and the “certain object A being disposed on the certain object B” include the “certain object A being directly disposed at the certain object B” and the “certain object A being disposed at the certain object B while another object is interposed between the certain object A and the certain object B.” Similarly, unless otherwise noted, the “certain object A being located on the certain object B” includes the “certain object A being located on the certain object B with the certain object A in contact with the certain object B” and the “certain object A being located on the certain object B while another object is interposed between the certain object A and the certain object B.” In addition, unless otherwise noted, the “certain object A being superposed on the certain object B as viewed in a certain direction” includes the “certain object A being superposed on all of the certain object B” and the “certain object A being superposed on a part of the certain object B.” In addition, a “certain surface A facing in a direction B (one side or another side of the direction B)” in the present disclosure is not limited to a case where the angle of the surface A with respect to the direction B is 90°, and includes a case where the surface A is inclined with respect to the direction B.
The resistive element layer 10 is a main member that determines the resistance value of the shunt resistance A1. The resistive element layer 10 has the z-direction as a thickness direction thereof, and has a flat plate shape extending along the x-direction and the y-direction. A thickness t0 of the resistive element layer 10 is not limited to any value at all, and is equal to or more than 0.5 mm but equal to or less than 2.0 mm, for example. In the present embodiment, the resistive element layer 10 has a rectangular shape as viewed in the z-direction.
A material of the resistive element layer 10 is selected as appropriate according to, for example, the resistance value that the shunt resistance A1 is to have, a usage environment of the shunt resistance A1, and others. An example of the material of the resistive element layer 10 is a copper-based alloy or a nichrome-based alloy, and is, specifically, a Cu—Mn—Sn alloy (Zeranin: registered trademark), a Cu—Mn—Ni alloy (Manganin: registered trademark), a Cu—Ni alloy (GCN49: Tokyo Resistance Wire Co., Ltd.), or a Ni—Cr alloy (NCH-1: Tokyo Resistance Wire Co., Ltd.).
The first electrode layer 11 is laminated on a first side (lower side in
A thickness t1 of the first electrode layer 11 is not limited to any value at all, and is equal to or more than 0.1 mm but equal to or less than 1.0 mm, for example. In addition, the shape and size of the first electrode layer 11 may be the same as those of the resistive element layer 10, or may be different from those of the resistive element layer 10. In the present embodiment, the first electrode layer 11 has a rectangular shape as viewed in the z-direction. As viewed in the z-direction, the outer edge of the resistive element layer 10 and the outer edge of the first electrode layer 11 coincide with each other. That is, the shape and size of the first electrode layer 11 as viewed in the z-direction are the same as those of the resistive element layer 10.
The first electrode layer 11 has a first mounting surface 111. The first mounting surface 111 faces the first side in the z-direction. As illustrated in
The second electrode layer 12 is laminated on a second side (upper side in
A thickness t2 of the second electrode layer 12 is not limited to any value at all, and is equal to or more than 0.1 mm but equal to or less than 2.0 mm, for example. In addition, the shape and size of the second electrode layer 12 may be the same as those of the resistive element layer 10, or may be different from those of the resistive element layer 10. In the present embodiment, the second electrode layer 12 has a rectangular shape as viewed in the z-direction. As viewed in the z-direction, the outer edge of the resistive element layer 10 and the outer edge of the second electrode layer 12 coincide with each other. That is, the shape and size of the second electrode layer 12 as viewed in the z-direction are the same as those of the resistive element layer 10.
The second electrode layer 12 has a second mounting surface 121. The second mounting surface 121 faces the second side in the z-direction. As illustrated in
An example of a method of manufacturing the shunt resistance A1 will next be described in the following with reference to
First, as illustrated in
Next, the laminated metallic material M is divided into individual pieces by being subjected to cutting processing along cutting lines CL. A plurality of shunt resistances A1 are thereby obtained.
Another example of the method of manufacturing the shunt resistance A1 will next be described in the following with reference to
First, as illustrated in
A specific method of this compression bonding is not limited to any kind at all, and adopted in the present example is a method which rolls the resistive element layer 10, the first electrode layer 11, and the second electrode layer 12 by a roller RL from both sides in the thickness direction of the resistive element layer 10. The laminated metallic material M including the resistive element layer 10, the first electrode layer 11, and the second electrode layer 12 is obtained by performing the rolling processing using the roller RL.
Thereafter, a plurality of shunt resistances A1 are obtained by, for example, dividing the laminated metallic material M illustrated in
There are no limitations at all on specific applications, for example, of the semiconductor device B1. In the semiconductor device B1, the first switching element 4 constitutes an upper arm circuit, and the second switching element 5 constitutes a lower arm circuit. A half-bridge circuit is thereby formed. The semiconductor device B1 constitutes, for example, an inverter for converting direct-current power into alternating-current power and supplying the power to a driving source such as a motor. Description will be made by taking as an example a case where the semiconductor device B1 according to the present embodiment includes one half-bridge circuit. However, the semiconductor device B1 may include, for example, three half-bridge circuits to supply power to what is generally called a three-phase alternating-current motor.
As illustrated in
The first insulating layer 20 is a layer having the z-direction as a thickness direction thereof. The first insulating layer 20 has an insulating property. The first insulating layer 20 is formed of ceramic, for example.
The first metal layer 25 is a layer having the z-direction as a thickness direction thereof. The first metal layer 25 is laminated on an opposite side in the z-direction of the first insulating layer 20 from the first conductive layer 21 and the third conductive layer 22. The first metal layer 25 includes Cu, for example.
The first substrate 2 is not limited to the above-described configuration, and may have a configuration in which the first insulating layer 20 and the first metal layer 25 are not provided, for example.
The second substrate 3 includes a second conductive layer 31, a fourth conductive layer 32, a second insulating layer 30, and a second metal layer 35, and is configured as, for example, a DBC substrate or an AMB substrate. The second conductive layer 31 is a layer having the z-direction as a thickness direction thereof. The second conductive layer 31 includes Cu, for example. The fourth conductive layer 32 is separated from the second conductive layer 31. The fourth conductive layer 32 is a layer having the z-direction as a thickness direction thereof. The fourth conductive layer 32 includes Cu, for example.
The second insulating layer 30 is a layer having the z-direction as a thickness direction thereof. The second insulating layer 30 has an insulating property. The second insulating layer 30 is formed of ceramic, for example.
The second metal layer 35 is a layer having the z-direction as a thickness direction thereof. The second metal layer 35 is laminated on an opposite side in the z-direction of the second insulating layer 30 from the second conductive layer 31 and the fourth conductive layer 32. The second metal layer 35 includes Cu, for example.
The second substrate 3 is not limited to the above-described configuration, and may have a configuration in which the second insulating layer 30 and the second metal layer 35 are not provided, for example.
The first conductive layer 21 and the second conductive layer 31 at least partly face each other in the z-direction. In addition, a part of the third conductive layer 22 and a part of the second conductive layer 31 face each other in the z-direction. In addition, the third conductive layer 22 and the fourth conductive layer 32 at least partly face each other in the z-direction.
A plurality of first switching elements 4 are formed by use of a semiconductor material. The semiconductor material may be, for example, silicon carbide (SiC), silicon (Si), gallium arsenide (GaAs), gallium nitride (GaN), or another material. In addition, in the present embodiment, each of the first switching elements 4 is a metal-oxide-semiconductor field-effect transistor (MOSFET). It is to be noted that the plurality of first switching elements 4 are not limited to the MOSFET, and may be a FET including a metal-insulator-semiconductor FET (MISFET), for example. The first switching elements 4 each include a first drain electrode 41, a first source electrode 42, and a first gate electrode 43. The first drain electrode 41 is disposed on an opposite side in the z-direction from the first source electrode 42 and the first gate electrode 43.
The first switching element 4 is disposed between the first conductive layer 21 and the second conductive layer 31 in the z-direction. The first drain electrode 41 is conductively bonded to the first conductive layer 21. The first source electrode 42 is conductively bonded to the second conductive layer 31. A method of the abovementioned conductive bonding is not limited to any kind at all, and, for example, solder bonding, bonding using a fired silver material, solid phase diffusion bonding, or another method of conductive bonding is used as appropriate.
A plurality of second switching elements 5 are formed by use of a semiconductor material. The semiconductor material may be, for example, SiC, Si, GaAs, GaN, or another material. In addition, in the present embodiment, each of the second switching elements 5 is a MOSFET. It is to be noted that the plurality of second switching elements 5 are not limited to the MOSFET, and may be a FET including a MISFET, for example. The second switching elements 5 each include a second drain electrode 51, a second source electrode 52, and a second gate electrode 53. The second drain electrode 51 is disposed on an opposite side in the z-direction from the second source electrode 52 and the second gate electrode 53.
The second switching element 5 is disposed between the third conductive layer 22 and the second conductive layer 31 in the z-direction. The second drain electrode 51 is conductively bonded to the second conductive layer 31. The second source electrode 52 is conductively bonded to the third conductive layer 22. A method of the abovementioned conductive bonding is not limited to any kind at all, and, for example, solder bonding, bonding using a fired silver material, solid phase diffusion bonding, or another method of conductive bonding is used as appropriate.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
The shunt resistance A1 may have a configuration illustrated in
The detection terminals 86 and 87 are terminals used for current detection using the shunt resistance A1. The detection terminal 86 is, for example, conductively bonded to the third conductive layer 22. The detection terminal 87 is, for example, conductively bonded to the fourth conductive layer 32.
A sealing resin 7 covers at least a part of each of the first substrate 2, the second substrate 3, the first switching element 4, the second switching element 5, the positive electrode terminal 81, the negative electrode terminal 82, the output terminal 83, the first gate terminal 84, the second gate terminal 85, and the detection terminals 86 and 87. The sealing resin 7 has an insulating property. The sealing resin 7 includes epoxy resin, for example.
A part of each of the positive electrode terminal 81, the negative electrode terminal 82, the output terminal 83, the first gate terminal 84, the second gate terminal 85, and the detection terminals 86 and 87 projects from the sealing resin 7. However, there are no limitations at all on specific configurations of the positive electrode terminal 81, the negative electrode terminal 82, the output terminal 83, the first gate terminal 84, the second gate terminal 85, and the detection terminals 86 and 87, and various configurations can be adopted as long as the configurations allow electric connection to the outside.
One surface of each of the first metal layer 25 and the second metal layer 35 is exposed from the sealing resin 7.
In a case where a three-phase alternating current motor is supplied with power, a configuration which includes three sets of the first switching element 4, the second switching element 5, and the output terminal 83 may be adopted.
The first gate terminal 84 is a terminal for the switching control of the first switching element 4. The second gate terminal 85 is a terminal for the switching control of the second switching element 5.
The detection terminals 86 and 87 are terminals for electrically connecting, in parallel with the shunt resistance A1, a detector (not illustrated) for detecting a current flowing through the shunt resistance A1.
Actions of the shunt resistance A1 and the semiconductor device B1 will next be described.
According to the present embodiment, the shunt resistance A1 has the first electrode layer 11 and the second electrode layer 12 arranged on both sides in the thickness direction with the resistive element layer 10 interposed therebetween. Thus, as illustrated in
The first electrode layer 11 has the first mounting surface 111. The second electrode layer 12 has the second mounting surface 121. Thus, the mounting target object C is disposed in such a manner as to be superposed on the shunt resistance A1 as viewed in the z-direction. This is preferable in reducing the size in the x-direction and the y-direction of the mounting structural body described above.
The semiconductor device B1 has the shunt resistance A1 disposed between the first substrate 2 and the second substrate 3 in the z-direction. It is thus possible to avoid an increase in the size in the x-direction or the y-direction due to the provision of the shunt resistance A1 in the semiconductor device B1. Hence, a miniaturization of the semiconductor device B1 can be achieved.
The shunt resistance, the method of manufacturing the shunt resistance, and the semiconductor device according to an embodiment of the present disclosure are not limited to those in the foregoing embodiment. The specific configurations of the shunt resistance, the method of manufacturing the shunt resistance, and the semiconductor device according to an embodiment of the present disclosure are capable of being changed in design in various manners.
A shunt resistance including:
The shunt resistance according to supplement 1, in which the first electrode layer has a first mounting surface that faces the first side in the thickness direction.
The shunt resistance according to supplement 2, in which the second electrode layer has a second mounting surface that faces the second side in the thickness direction.
The shunt resistance according to supplement 3, in which,
The shunt resistance according to supplement 3 or 4, in which,
The shunt resistance according to any one of supplements 3 to 5, in which
The shunt resistance according to any one of supplements 3 to 6, in which
The shunt resistance according to any one of supplements 3 to 7, in which
A semiconductor device including:
The semiconductor device according to supplement 9, in which
The semiconductor device according to supplement 9 or 10, in which
The semiconductor device according to supplement 11, further including:
A method of manufacturing a shunt resistance, the method including:
A method of manufacturing a shunt resistance, the method including:
Number | Date | Country | Kind |
---|---|---|---|
2023-116451 | Jul 2023 | JP | national |